Applications where sensor contact is unavoidable are some of the most challenging to solve. Metal forming processes involving over travel can also damage or even destroy a sensor causing failure and expensive unplanned downtime. Manufacturers often try to remedy this with in-house manufactured spring loaded out-feed mechanisms but those are expensive to make by experienced tool and die personnel who have more important things to do . Over the years, I’ve seen this as a pervasive problem in the stamping industry. Many of these issues can be solved with the use of a simple yet effective sensor actuator system known as a plunger probe.
Plunger probe solves a few key issues in Progressive stamping:
- The flexible trigger/actuation point is fully adjustable to meet sensitive or less sensitive activation points, not possible with “fixed” systems with substantial “over travel” built into the design.
- It is fully self-contained (minimizing any risk of sensor damage and resulting unplanned machine down time).
- The device can be disassembled and rapidly cleaned, reassembled, and placed back in service in the event that die lube or other industrial fluids enter the M18 body that can potentially congeal during shut down periods.
See me demo this product in the following video:
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Post Process Check Stations – Mechanical Contact with PlungerProx sensor. This sensor uses a spring loaded pin sized for the proper nut to detect presence, is easily repairable (if necessary) and has the ability to adapt to a wide range of nut threads and diameters.
In-Process Check on Pedestal Welders – 
